Orlando

Roof Front Header Panel Replacement - Brazing

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

Warning : Refer to Collision Sectioning Warning in the Preface section.

Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .



6. Locate and mark all the necessary factory welds of the roof panel front bracket right (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



8. Remove the roof panel front bracket right (1).
9. Proceed the same way with the roof panel front bracket left.



10. Create cut lines on the roof front header panel.



11. Cut the panel where sectioning is to be performed.



12. Remove the damaged roof front header panel.

1. Cut the roof front header panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate from the unused portion of the service part.
3. Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart.
4. Prepare all mating surfaces as necessary.
5. Fit the backing plates halfway into the sectioning joints, clamp in place and braze to the vehicle.
6. Align roof front header panel.



7. Braze accordingly.
8. To create a solid braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch braze.



9. Create 6 x 20 mm (4/16 x 12/16 in) slots for MIG-brazing along the edges of the roof panel front bracket right.
10. Clean and prepare the attaching surfaces for brazing.



11. Position the roof panel front bracket right (1) on the vehicle.
12. Verify the fit of the roof panel front bracket.
13. Clamp the roof panel front bracket right into position.



14. Braze accordingly.
15. Proceed the same way with the roof panel front bracket left.
16. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
17. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
18. Install all related panels and components.
19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
20. Enable the SIR system. Refer to SIR Disabling and Enabling .